INFORMATION

SURFACE PREPARATION OF CONCRETE

(FLOORS) 1496

a three page issue June 2013

revision of February 2009

GENERAL ASPECTS
Once a coating or a polymer flooring has been selected it is essential that the surface preparation of
concrete is done correctly, otherwise optimum performance will not be obtained.

New concrete: In the case of newly made concrete it is important that the concrete has been laid for a
minimum of 28 days before applying a coating or polymer flooring. The moisture content of the concrete
should be below 4 % by weight. The release of the surplus water is dependant on the thickness of the
concrete, the season, the temperature and relative humidity of the environment and the prevailing
ventilation conditions. So the moisture content of the concrete should always be measured.
The moisture content at the concrete surface can be measured by an electronic instrument called Protimeter
(Protimeter plc, U.K. telex 849305).
An indication in the red area means that the concrete is still too wet.
An indication in the green area means that the concrete can be coated.
An indication in the yellow area means be careful. A concrete area of approx. 4 m² should be covered by a
plastic sheet for 24 hours after which the measurement has to be repeated. If the indication becomes red
then the subfloor is still too wet to apply a flooring.
A major problem with new concrete floors is the top surface layer known as laitance. This water rich top
layer is formed during the binding period and is mechanically weak. In addition to the poor mechanical
properties, the laitance has a chemical composition different from the rest of the concrete. Concrete floors
with this laitance are obviously poor substrates to apply coatings to. It should therefore be a pre-condition
that the laitance has been removed prior to the application of any floor coating or polymer flooring.
Old concrete: The removal of all oils, greases etc., together with the removal of the remains of any
previously applied coating is required to ensure a sound base for the application of a coating, polymer
flooring or screed.

SURFACE PREPARATION
In order to ensure good adhesion and the long term performance of any floor coating or polymer flooring it is
essential that the correct type of surface preparation is carried out. The removal of chemicals, oil, grease
and fat must be completed before any other preparation work commences such as e.g. blasting or acid
etching (ASTM D4259 or ASTM D4260).
Mechanical tool cleaning must always be followed by removal of dust by means of vacuum cleaners.
Removal of chemicals from floor surfaces: Concrete that has become contaminated by chemicals must be
neutralised before coating. If the contamination is acidic, it must be neutralised with an alkaline cleaner and
rinsed thoroughly with fresh water.
If the contamination is alkaline it can be cleaned with detergents and/or steam.
Oil and grease contamination can be removed by a combination of solvents, steam and/or detergents
depending on the severity of the contamination.

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 INFORMATION
SURFACE PREPARATION OF CONCRETE
(FLOORS) 1496

February 2009

Abrasive blast cleaning: Abrasive blast cleaning should always be the best choice for the pretreatment of
concrete if polymer flooring systems have to be applied. Blast cleaning is normally carried out using an
enclosed system such as a Vacu-Blast, or Auto-Blast type machine. These systems are virtually dust free
and work on the principal of propelling small particles of abrasive i.e. steel shot, against the floor surface
whilst at the same time vacuum recovering the dust and abrasive to a recovery hopper. In addition to
cleaning the floor and removing any laitance, blasting will leave the floor surface with a profile which will
enable the coating to gain a physical as well as chemical adhesion to the substrate. Blast cleaning is the
recommended system for large floor areas.
Scarifying: Scarifying (sometimes known as scabbling) involves the use of rotating wheels and brushes to
scour the concrete surface. The scarifying equipment is pushed over the floor and the enclosed rotating
wheels abrade the surface. It is not as efficient or as dust free as a Vacu-Blast machine and can in the
wrong hands, cause excessive damage to the substrate. It is most effective on small areas or areas where
abrasive blast cleaning cannot be carried out.
Power grinding: Similar to scarifying this method can be used to open up holes and voids and to remove
loose materials from the surface of poured concrete and pre-cast slabs. Power grinding is slower than
blasting but could be considered for small external floor areas. One should take care that the concrete
surface is not polished by the power grinding.
Wire brushing: Wire brushing can be used to remove loose material from the surface and open up holes and
voids in poured concrete. This can be either by power or hand wire brushing, power wire brushing giving
increased productivity and effectiveness.
Impact tools: Concrete surfaces can be roughened using impact tools such as needle guns etc. However this
method can be slow and should only be used for small repairs.
Granulating or Hammering machines work quicker but should only be used if very hard concrete must be
roughened or if flooring screeds have to be applied.
Impact tools are normally electrically or compressed air driven and work on a principal of a sharpened tool
vibrating against the surface. It is fairly easy for an inexperienced operative to gouge the concrete surface
and therefore great care should be taken when using this method of preparation.
Acid etching: This method of surface preparation is most suited for use on new concrete floors (not for
sand/cement screeds). It is carried out to remove laitance but will not remove old paint or oil and grease and
should only be used in areas where sufficient drainage exists to allow the removal of the water and acid
solutions. To carry out acid etching the following procedure should be followed:
– Before commencing acid etching the concrete surface should be cleaned of all loose concrete. Deposits
of
oil and grease should be removed by steam cleaning or by using an alkaline cleaner or detergents.
– Thoroughly wet the floor with water
– Sprinkle an 8% to 10% solution of phosphoric acid in water uniformly over the floor. The approximate
spreading rate is 1,5 m² to 1 litre of solution.

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 INFORMATION
SURFACE PREPARATION OF CONCRETE
(FLOORS) 1496

February 2009

– The acid solution should remain on the surface for 2 to 4 minutes and then be rinsed thoroughly with
clean water. The rinsing can be done with a water hose and a sweeping broom.
– It is important that the rinsing is done immediately to prevent the formation of salts on the surface, which
are difficult to remove.
– The concrete surface should be checked for acidity using pH paper and should have a pH of 7 or higher.
– Depending on the type of concrete, more than one operation may be required to achieve a satisfactory
surface profile.
– A thorough rinsing with clean water should be carried out after each acid etch application. The surface
profile after acid etching should be similar to fine sandpaper.
– The concrete should be allowed to dry prior to applying the coating.
Personnel involved in acid etching operations should be provided with safety goggles, protective clothing,
rubber gloves and rubber boots.
Rubber buckets should be used for mixing the solution. THE ACID SHOULD ALWAYS BE ADDED TO THE
WATER rather than the water added to the acid.
Flame cleaning: Where conditions permit, deeply impregnated oils and greases can be removed from
concrete floors by flame or superheated compressed air.
This method involves the use of heat to bring the oil, grease etc. to the surface and should be carried out
under strict supervision with the necessary precautions being taken in view of the possible hazards
involved.
After flame cleaning the surface should always be power tool cleaned.

Limitation of Liability - IN NO EVENT WILL PPG BE LIABLE UNDER ANY THEORY OF RECOVERY (WHETHER BASED
ON NEGLIGENCE OF ANY KIND, STRICT LIABILITY OR TORT) FOR ANY INDIRECT, SPECIAL, INCIDENTAL, OR
CONSEQUENTIAL DAMAGES IN ANY WAY RELATED TO, ARISING FROM, OR RESULTING FROM ANY USE MADE OF
THE PRODUCT. The information in this sheet is intended for guidance only and is based upon laboratory tests
that PPG believes to be reliable. PPG may modify the information contained herein at any time as a result of
practical experience and continuous product development. All recommendations or suggestions relating to the
use of the PPG product, whether in technical documentation, or in response to a specific inquiry, or otherwise,
are based on data, which to the best of PPG’s knowledge, is reliable. The product and related information is
designed for users having the requisite knowledge and industrial skills in the industry and it is the end-user’s
responsibility to determine the suitability of the product for its own particular use and it shall be deemed that
Buyer has done so, as its sole discretion and risk. PPG has no control over either the quality or condition of the
substrate, or the many factors affecting the use and application of the product. Therefore, PPG does not accept
any liability arising from any loss, injury or damage resulting from such use or the contents of this information
(unless there are written agreements stating otherwise). Variations in the application environment, changes in
procedures of use, or extrapolation of data may cause unsatisfactory results. This sheet supersedes all previous
versions and it is the Buyer’s responsibility to ensure that this information is current prior to using the product.
Current sheets for all PPG Protective & Marine Coatings Products are maintained at www.ppgpmc.com. The
English text of this sheet shall prevail over any translation thereof.

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